Impact dispersion systems and methods

ABSTRACT

An impact assembly for protecting a wearer comprises a plurality of impact parts. Each impact part defines a main portion, a first connecting portion, and a second connecting portion. The main portion defines a first surface and a second surface. The first and second connecting portions of a plurality of the impact parts are connected to define a plurality of strings of impact parts. The plurality of strings of impact parts are arranged such that the second surface of the main portion of the some of the impact parts partly overlay the first surface of the main portion of others of the impact parts.

RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Application Ser. No.61/126,753 filed May 5, 2008.

The subject matter of the foregoing related application is incorporatedherein by reference.

TECHNICAL FIELD

The present invention relates to systems and methods for dispersingimpacts and, more specifically, to impact dispersion systems and methodsthat allow improved freedom of movement.

BACKGROUND

In many common activities, individuals are subjected to impacts fromobjects and/or other individuals. For example, in martial arts,participants strike each other with hands, feet, elbows, knees, weapons,and the like while sparring. As another example, soccer players areoften kicked in the shins during normal play. As yet another example,workers performing many jobs may be struck by tools, workpieces, or thelike.

To protect the human body from such impacts, devices have been developedto protect vulnerable parts of the body. Protective devices typicallycomprise a pad or pad assembly and a support structure. The pad or padassembly absorbs impacts, while the support structure holds the pad orpad assembly in place over the vulnerable body part.

For less sensitive parts of the body or situations in which expectedimpacts are less severe, the protective device may use a simple foam padthat compresses to absorb the expected impacts. The amount of impactthat can be absorbed by a pad alone is dependent upon the thickness ofthe pad. For severe impacts, a pad capable of absorbing such impacts maybe too bulky for practical used.

Accordingly, for more sensitive parts of the body or situations in whichthe expected impacts are more severe, the protective device typicallycomprises a pad assembly comprising an inner, compressible foam pad andan outer, relative rigid shell member. As an example, a shin guard foruse by a soccer player typically comprises a pad assembly comprising afoam pad and molded plastic shell. An impact on the pad assembly firstencounters the plastic shell; the plastic shell distributes the force ofthe impact over a wider area to prevent the impact from being narrowlytransmitted to the shin. Once the impact has been distributed over thewider area, a relatively thin foam pad is capable of absorbing theimpact before the impact is transmitted to the shin.

Protective devices comprising a pad assembly employing a foam pad andmolded plastic shell can restrict movement of the individual wearing theprotective device. The plastic shell, being relatively rigid, does noteasily accommodate parts of the body, such as knees, elbows, and thelike, that require movement. Even relatively inflexible parts of thebody, such as the shin or back, may move or be connected to moving partsof the body such that overall movement of the individual is restricted.

The need thus exists for protective devices for the human body capableof optimizing the absorption of impacts while minimizing the restrictionof movement of the body.

SUMMARY

The present invention may be embodied as an impact assembly forprotecting a wearer comprising first, second, and third impact parts.Each impact part defines a main portion, a first connecting portion, anda second connecting portion. The main portion defines a first surfaceand a second surface. The first connecting portion of the first impactpart engages the second connecting portion of the second impact part.The second surface of the main portion of the first impact part partlyoverlays the first surface of the main portion of the third impact part.The second surface of the main portion of the third impact part partlyoverlays the first surface of the main portion of the second impactpart.

The present invention may also be embodied as an impact dispersionsystem for protecting a wearer comprising an impact assembly and asupport structure. The impact assembly comprises first, second, andthird impact parts. Each impact part defines a main portion, a firstconnecting portion, and a second connecting portion. The main portiondefines a first surface and a second surface. The support structuresupports the impact assembly over a desired area on the wearer. Thefirst connecting portion of the first impact part engages the secondconnecting portion of the second impact part. The second surface of themain portion of the first impact part partly overlays the first surfaceof the main portion of the third impact part. The second surface of themain portion of the third impact part partly overlays the first surfaceof the main portion of the second impact part.

The present invention may also be embodied as an impact assembly forprotecting a wearer comprising a plurality of impact parts each defininga main portion, a first connecting portion, and a second connectingportion. The main portion defines a first surface and a second surface.The first and second connecting portions of a plurality of the impactparts are connected to define a plurality of strings of impact parts.The plurality of strings of impact parts are arranged such that thesecond surface of the main portion of the some of the impact partspartly overlay the first surface of the main portion of others of theimpact parts.

The present invention may also be embodied as an impact assembly forprotecting a wearer comprising a plurality of impact parts each defininga main portion, a connecting opening, and a connecting tab. Each mainportion defines a first surface and a second surface, and at least onelateral projection extends from the second surface of the each mainportion. The connecting openings engage the connecting tabs to define aplurality of strings of impact parts. The plurality of strings of impactparts are arranged such that the second surface of the main portion ofthe some of the impact parts partly overlay the first surface of themain portion of others of the impact parts. At least one lateralprojection extends through at least one connecting opening and engagesthe first connecting portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a somewhat schematic, exploded, perspective view of an exampleimpact dispersion system of the present invention;

FIG. 2 is a somewhat schematic, exploded, perspective view of a firstexample impact assembly that may be used by an impact dispersion systemof the present invention;

FIG. 3 is an exploded, front, perspective view illustrating theengagement of a plurality of first example impact parts that arecombined to form a first example impact assembly that may be used by thean impact dispersion system of the present invention;

FIG. 4 is a rear, perspective view illustrating the engagement of aplurality of first example impact parts as depicted in FIG. 3 to form atleast a portion of the first example impact assembly;

FIG. 5 is a rear, perspective view illustrating the combination of thefirst example impact assembly of FIGS. 3 and 4 and an example backinglayer;

FIG. 6 is perspective view illustrating the engagement of a plurality ofsecond example impact parts that are combined to form a second exampleimpact assembly that may be used by an impact dispersion system of thepresent invention;

FIGS. 7A-7D are perspective, top plan, end elevation, and side elevationviews, respectively, illustrating one of the second example impact partsforming the second example impact assembly of FIG. 6;

FIG. 8 is a somewhat schematic, perspective front view of a borderportion of a third example impact assembly that may be used by an impactdispersion system of the present invention;

FIG. 9 is a somewhat schematic, perspective rear view of the thirdexample impact assembly depicted in FIG. 8;

FIG. 10 is a perspective rear view depicting the interconnection of afield impact part that may be used by the third example impact assemblyof FIGS. 8 and 9;

FIGS. 11A and 11B are rear and front perspective views of the of fieldimpact part depicted in FIG. 10;

FIG. 12A is a perspective view of a first border impact part of thethird example impact assembly of FIGS. 8 and 9;

FIG. 12B is a top plan view of the first border impact part depicted inFIG. 12A;

FIG. 12C is a bottom plan view of the first border impact part depictedin FIG. 12A;

FIG. 12D is a side elevation view of the first border impact partdepicted in FIG. 12A;

FIG. 13A is a perspective view of a second border impact part of thethird example impact assembly of FIGS. 8 and 9;

FIG. 13B is a top plan view of the second border impact part depicted inFIG. 13A;

FIG. 13C is a bottom plan view of the second border impact part depictedin FIG. 13A;

FIG. 13D is a side elevation view of the second border impact partdepicted in FIG. 13A;

FIG. 14A is a perspective view of a third border impact part of thethird example impact assembly of FIGS. 8 and 9;

FIG. 14B is a top plan view of the third border impact part depicted inFIG. 14A;

FIG. 14C is a bottom plan view of the third border impact part depictedin FIG. 14A;

FIG. 14D is a side elevation view of the third border impact partdepicted in FIG. 14A;

FIG. 15A is a perspective view of a fourth border impact part of thethird example impact assembly of FIGS. 8 and 9;

FIG. 15B is a top plan view of the fourth border impact part depicted inFIG. 15A;

FIG. 15C is a bottom plan view of the fourth border impact part depictedin FIG. 15A;

FIG. 15D is a side elevation view of the fourth border impact partdepicted in FIG. 15A;

FIG. 16A is a perspective view of a fifth border impact part of thethird example impact assembly of FIGS. 8 and 9;

FIG. 16B is a top plan view of the fifth border impact part depicted inFIG. 16A;

FIG. 16C is a bottom plan view of the fifth border impact part depictedin FIG. 16A;

FIG. 16D is a side elevation view of the fifth border impact partdepicted in FIG. 16A;

FIG. 17A is a perspective view of a sixth border impact part of thethird example impact assembly of FIGS. 8 and 9;

FIG. 17B is a top plan view of the sixth border impact part depicted inFIG. 17A;

FIG. 17C is a bottom plan view of the sixth border impact part depictedin FIG. 17A;

FIG. 17D is a side elevation view of the sixth border impact partdepicted in FIG. 17A;

FIG. 18A is a perspective view of a seventh border impact part of theseventh example impact assembly of FIGS. 8 and 9;

FIG. 18B is a top plan view of the seventh border impact part depictedin FIG. 18A;

FIG. 18C is a bottom plan view of the seventh border impact partdepicted in FIG. 18A; and

FIG. 18D is a side elevation view of the seventh border impact partdepicted in FIG. 18A.

DETAILED DESCRIPTION

Referring initially to FIG. 1 of the drawing, depicted therein is afirst example impact system 20 comprising an impact assembly 22 and asupport assembly 24. The impact system 20 is adapted to protect apredetermined area of a wearer. The first example impact system 20 is ashin guard designed to be worn over and protect the wearer's shin, butthe impact system 20 may take many different shapes and sized dependingupon the particular predetermined area to be protected.

The example pad assembly 22 comprises an impact layer 30 and a resilientpad 32. The example support assembly 24 comprises a first panel 40 and asecond panel 42. The first panel 40 is a substantially conical orcylindrical form that defines a passageway 44. The second panel 42 issecured to the first panel 40 to define a pocket 46. The pad assembly 22defines a form factor adapted to overlay the predetermined area of thewearer, and the pocket 46 is sized and dimensioned to receive the padassembly 22.

With the pad assembly 22 received by the pocket 46, the passageway 44receives a portion of the wearer such that the pad assembly 22 is heldin place over the predetermined area of the wearer. The first exampleimpact system 20 is a shin guard, so the wearer's foot is passed throughthe passageway 44, and the support assembly 24 is pulled up so thatfirst panel 40 surrounds the wearer's leg below the knee. The pocket 46is arranged towards the front so that the pad assembly 22 overlays andprotects the wearer's shinbone. At least the first panel 40 is made of astretchable memory material or fabric that snugly holds the pad assembly22 in place over the wearer's shinbone.

The impact layer 30 may be made in many different sizes and shapes andof many different materials. For example, the impact dispersion system20 may be designed to cover different predetermined areas of the wearer,such as the knees, elbows, hips, back, head, legs, chest, and/or otherextremities of the body. For each different protected area, the size andshape of the impact layer 30 will be different. The impact layer 30 mayfurther be customized for different sizes of individuals. Depending uponthe nature of the impact system 20, a single support system may compriseone or more impact assemblies, with or without a pad.

In addition, the impact layer may be made at least in part of plasticfor contact sports such as soccer or hand-to-hand sparring. However, theimpact layer may be made at least in part of more durable materials suchas metals and composites if the impact layer is used to protect thewearer from weapons.

Several example impact assemblies that may be used as part of an impactdispersion system of the present invention will be described in furtherdetail below.

Referring initially to FIGS. 2-5, a first example impact assembly 220 isdepicted therein. The first example impact assembly 220 comprises animpact layer 222 and a backing layer 224 comprising a structural sheet226 and a foam sheet 228. The example structural sheet 226 is made of asheet of Kevlar, while the example foam sheet 228 is made of sheet ofneoprene. The example sheets 226 and 228 are laminated or otherwisejoined together to form the backing layer 224; these sheets 226 and 228may further be processed as will be described in further detail below tofacilitate connection of the impact layer 222 to the backing layer 224.

As shown in FIGS. 2-6, the impact layer 222 comprises a plurality ofinterconnected impact parts 230. The example impact parts 230 areidentical and each comprises a main portion 232, a first connectingportion 234, and a second connecting portion 236. The main portion 232defines a front surface 240, a rear surface 242, and a perimeter edge244.

The first connecting portion 234 defines a connecting opening 250defining a bridge portion 252. The second connecting portion 236 definesa connecting tab 254 and a neck portion 256. The connecting tab 254 isadapted to extend through the connecting opening 250. The example impactparts 230 further define first and second lateral projections 260 and262 that extend from the rear surface 242. The lateral projections 260and 262 each define an inward facing curved surface portion 264 and anoutward facing flat surface portion 266.

When the impact parts 230 are connected as shown in FIG. 5, a proximalportion 256 a of the neck portion 256 of a first impact part 230 a liesunder the bridge portion 252 and a distal portion 256 b of the neckportion 256 lies within the connecting opening 250 of a second impactpart 230 b. Additionally, the lateral projections 260 of laterallyadjacent impact parts 230 c and 230 d also extend into the connectingopening 250 of the second impact part 230 b. The curved surface portions264 of the laterally adjacent parts 230 c and 230 d engage the firstconnection portion 234 of the second part 230 b. The flat surfaceportions 266 of the lateral adjacent parts 230 a and 230 d engage thedistal portions 254 a of the neck portion 256 of the first part 230 a.

Accordingly, as shown in FIG. 5, the first and second connectingportions 234 and 236 of the impact parts 230 a and 230 b, the firstlateral projection 260 of the first laterally adjacent impact part 230c, and the second lateral projection 262 of the second laterallyadjacent impact part 230 d form a connecting system 270. The connectingsystem 270 joins the impact parts 230 a, 230 b, 230 c, and 230 dtogether into a unit 272 as shown in FIG. 5. Additionally, it should beapparent that multiple additional impact parts 230 may be added to theunit 272 to form an even larger impact layer 222.

Additionally, the perimeter edges 244 of the first example impact parts230 forming the impact layer 222 of the first example impact assembly220 are formed such that the rear surface 242 of one part 230 overlapsthe front surface 240 of at least one adjacent part 230. Accordingly,the force arising from an impact applied to the front surface 240 of atarget impact part 230 is transmitted to adjacent impact parts 230 andfrom these adjacent impact parts 230 to impact parts that are notadjacent to the target impact part. This transfer of forces distributesthe force of the impact over a relatively wide surface area. However,the edges 244 are contoured such that impact layer 222 has a significantgreater degree of flexibility than a single piece of relatively rigidplastic.

Accordingly, both the size of the main portions 232 of the parts 230 andthe number of the parts 230 may be adjusted to obtain an impact layer222 having a desired size, shape, and degree of flexibility.

Additionally, as shown in FIG. 5 of the drawing, perforations 280 may beformed in the backing layer 224 at locations aligned with the locationsof the connecting systems 270 defined by the impact layer 222. Toassemble the impact layer 222 with the backing layer 224, each secondconnecting portion 236 is arranged such that the connecting openings 250are aligned with one of the perforations 280 in the backing layer 224.The first connecting portion 234 is then arranged such that theconnecting tabs 256 extend through both the connecting opening 250 andthe perforation 280 aligned therewith. The lateral projections 260 and262 are also inserted through the connecting opening 250 and theperforation 280 such that the connecting system 270 is formed.

The connecting system 270 thus not only holds the impact parts 230together to form the impact layer 222, but also holds the impact layerand the backing layer 224 together. As an alternative or in addition, anadhesive may be used to secure the backing layer 224 to the impact layer222.

Turning now to FIGS. 6 and 7 of the drawing, depicted therein is asecond example impact layer 320 of the present invention. The impactlayer 320 comprises a plurality of interconnected impact parts 330. Theexample impact parts 330 are identical and each comprises a main portion332, a first connecting portion 334, and a second connecting portion336. The main portion 332 defines a front surface 340, a rear surface342, and a perimeter edge 344.

The first connecting portion 334 defines a connecting opening 350. Thesecond connecting portion 336 defines a neck portion 352 and aconnecting tab 354. The connecting tab 354 is adapted to extend throughthe connecting opening 350.

When the impact parts 330 are connected as shown in FIG. 6, the neckportion 352 of a first impact part 330 a lies within the connectingopening 350 of a second impact part 330 b. Accordingly, the first andsecond connecting portions 334 and 336 of the impact parts 330 a and 330b form a connecting system 360. The connecting system 360 joins theimpact parts 330 together into a unit 362 as shown in FIG. 6.Additionally, it should be apparent that multiple additional impactparts 330 may be added to the unit 362 to form an even larger impactlayer 320.

FIG. 6 illustrates that the first and second connecting portions 334 and336 form strings 370 a-h of longitudinally connected impact parts 330.These strings 370 a-h are combined such that the parts 330 in one stringare offset from the parts of each adjacent string. The parts 330 thusengage each other like a woven fabric to create the larger impact layer330. Again, a backing layer or boundary layer may be mused to maintainthe strings 370 of parts together as part of the overall impact layer320.

Additionally, the perimeter edges 344 of the first example impact parts330 forming the impact layer 320 of the second example impact assembly320 are formed such that the rear surface 342 of one part 330 overlapsthe front surface 340 of at least one adjacent part 330. Accordingly,the force arising from an impact applied to the front surface 340 of atarget impact part 330 is transmitted to adjacent impact parts 330 andfrom these adjacent impact parts 330 to impact parts that are notadjacent to the target impact part. This transfer of forces distributesthe force of the impact over a relatively wide surface area. However,the edges 344 are contoured such that impact layer 320 has a significantgreater degree of flexibility than a single piece of relatively rigidplastic.

One advantage arising from the use of the impact parts 330 is that theimpact layer 320 facilitates transmission of heat away from the wearerthrough the impact layer 320. Initially, as perhaps best shown in FIGS.7C and 7D, the impact parts 330 are cupped such that the rear surfaces342 are slightly concave. When the impact layer 320 moves, such as toaccommodate movement of the wearer or upon external impacts, thecup-shaped impact parts 330 slightly deflect or deform to form a slightsuction that pulls heat and moist air away from the wearer. In addition,the shapes of the impact parts 330 (e.g., pointed oval with slightinward curves towards the pointed ends) creates spacing between eachadjacent part 330. Once the air has been forced out by the deflection ordeformation of the parts 330, the air travels through the spacingsbetween the interconnected parts 330.

Additionally, the example impact layer 320 may be used with a backingsheet such as the backing sheet 224 described above. The perforations insuch a backing sheet may be aligned with the impact layer 320 such thatair can be drawn from the inside of the backing sheet to the exterior,which ventilates the protected portion of the wearer under the impactlayer 320.

Again, both the size of the main portions 332 of the parts 330 and thenumber of the parts 330 may be adjusted to obtain an impact layer 320having a desired size, shape, and degree of flexibility. The individualimpact parts 330 can easily be injection molded of plastic; othermanufacturing techniques and materials can be used, however, dependingupon the expected use of the impact layer.

Referring now to FIGS. 8-18, depicted therein is a third example impactlayer 420 constructed in accordance with the principles of the presentinvention. The third example impact layer 420 comprises a field portion422 (e.g., FIG. 10) and a border portion 424.

The field portion 422 of the third example impact layer 420 comprises aplurality of interconnected field impact parts 430. The example fieldimpact parts 430 are identical and each comprises a main portion 432, afirst connecting portion 434, and a second connecting portion 436. Themain portion 432 defines a front surface 440, a rear surface 442, and aperimeter edge 444.

The first connecting portion 434 defines a connecting opening 450defining a bridge portion 452. The second connecting portion 436 definesa neck portion 454 and a connecting tab 456. The connecting tab 456 isadapted to extend through the connecting opening 450. The example impactparts 430 further define first and second lateral projections 460 and462 that extend from the rear surface 442. The lateral projections 460and 462 each define an inward facing curved surface portion 464 and anoutward facing flat surface portion 466. Additionally, first and secondlatch portions 470 and 472 extend from the first and second lateralprojections 460 and 462, respectively.

When the impact parts 430 are connected as shown in FIG. 10, a proximalportion 454 a of the neck portion 454 of a first impact part 430 a liesunder the bridge portion 452 and a distal portion 454 b of the neckportion 454 lies within the connecting opening 450 of a second impactpart 430 b. Additionally, the lateral projections 460 of laterallyadjacent impact parts 430 c and 430 d also extend into the connectingopening 450 of the second impact part 430 b. The curved surface portions464 of the laterally adjacent parts 430 c and 430 d engage the firstconnection portion 434 of the second part 430 b. The flat surfaceportions 466 of the lateral adjacent parts 430 c and 430 d engage thedistal portions 454 a of the neck portion 454 of the first part 430 a.The first and second latch portions 470 and 472 extend over the firstconnecting portions 434 to inhibit inadvertent removal of the firstportion 434 from the second portion 436 associated therewith.

Accordingly, as shown in FIG. 10, the first and second connectingportions 434 and 436 of the impact parts 430 a and 430 b, the firstlateral projection 460 of the first laterally adjacent impact part 430c, and the second lateral projection 462 of the second laterallyadjacent impact part 430 d form a connecting system 474. The connectingsystem 474 joins the impact parts 430 a, 430 b, 430 c, and 430 dtogether into a unit 476 as shown in FIG. 10. Additionally, it should beapparent that multiple additional impact parts 430 may be added to theunit 476 to form an even larger impact layer 420.

Additionally, the perimeter edges 444 of the first example impact parts430 forming the impact layer 420 of the third example impact assembly420 are formed such that the rear surface 442 of one part 430 overlapsthe front surface 440 of at least one adjacent part 430. Additionally,when the impact parts 430 are assembled, the front surfaces 440substantially cover the connection points formed where each of theconnecting systems 474 are formed.

Accordingly, the force arising from an impact applied to the frontsurface 440 of a target impact part 430 is transmitted to adjacentimpact parts 430 and from these adjacent impact parts 430 to impactparts that are not adjacent to the target impact part. This transfer offorces distributes the force of the impact over a relatively widesurface area. However, the edges 444 are contoured such that impactlayer 420 has a significant greater degree of flexibility than a singlepiece of relatively rigid plastic.

Accordingly, both the size of the main portions 432 of the parts 430 andthe number of the parts 430 may be adjusted to obtain an impact layer420 having a desired size, shape, and degree of flexibility. Also, theindividual field impact parts 430 can easily be injection molded ofplastic; other manufacturing techniques and materials can be used,however, depending upon the expected use of the impact layer.

As shown in FIG. 8 of the drawing, the border portion 424 comprises aplurality of specialized border impact parts. The border impact partscan be used to form a more finished looking border than can beaccomplished simply by using the field impact parts 430 alone.

In particular, the example border portion 424 comprises an upper endborder part 480, a first upper side border part 482, a corner sideborder part 484, a first lower side border part 486, a lower end borderpart 490, a second lower side border part 492, and a second upper sideborder part 494.

As shown in FIGS. 12A-D, the upper end border part 480 comprises a mainportion 520 and a connection portion 522. The main portion defines afront surface 520 a, a rear surface 520 b, and a perimeter edge 520 c.Like the second connection portion 436, the connection portion 522defines a neck portion 522 a and a connecting tab 522 b. A loopstructure 524 defining a loop opening 524 b extends from the rearsurface 520 b. The perimeter edge 520 c is dimensioned to complement theperimeter edges of the first and second upper side border parts 482 and494.

As shown in FIGS. 13A-D, the first upper side border part 482 comprisesa main portion 530 and a connection portion 532. The main portiondefines a front surface 530 a, a rear surface 530 b, and a perimeteredge 530 c. Like the second connection portion 436, the connectionportion 532 defines a neck portion 532 a and a connecting tab 532 b.Loop structures 534 defining loop openings 534 b extend from the rearsurface 530 b. A lateral projection 536 that is substantially the sameas the lateral projections 460 and 462 described above also extends fromthe rear surface 530 b. The perimeter edge 530 c is dimensioned tocomplement the perimeter edges of the upper end border part 480 and thecorner side border part 484.

As shown in FIGS. 14A-D, the corner side border parts 484 comprises amain portion 540. The main portion defines a front surface 5 540 a, arear surface 540 b, and a perimeter edge 540 c. Loop structures 542defining loop openings 542 b extend from the rear surface 540 b. Alateral projection 544 that is substantially the same as the lateralprojections 460 and 462 described above also extends from the rearsurface 540 b. The perimeter edge 540 c is dimensioned to complement theperimeter edges of the first upper side border part 482 and the firstlower side border part 486.

As shown in FIGS. 15A-D, the first lower side border part 486 comprisesa main portion 550 and a connection portion 552. The main portiondefines a front surface 550 a, a rear surface 550 b, and a perimeter isedge 550 c. Like the first connecting portion 434, the connectingportion 552 defines a connecting opening 552 a defining a bridge portion552 b. Loop structures 554 defining loop openings 554 b extend from therear surface 550 b. A lateral projection 556 that is substantially thesame as the lateral projections 460 and 462 described above also extendsfrom the rear surface 550 b. The perimeter edge 550 c is dimensioned tocomplement the perimeter edges of the corner side border parts 484 andthe lower end border part 490.

As shown in FIGS. 16A-D, the lower end border part 490 comprises a mainportion 560 and a connection portion 562. The main portion 25 defines afront surface 560 a, a rear surface 560 b, and a perimeter edge 560 c.Like the first connecting portion 434, the connecting portion 562defines a connecting opening 562 a defining a bridge portion 562 b. Aloop structure 564 defining a loop opening 564 b extends from the rearsurface 560 b. The perimeter edge 560 c is dimensioned to complement the30 perimeter edges of the first lower side border part 486 and thesecond lower side border part 492.

As shown in FIGS. 17A-D, the second lower side border part 492 comprisesa main portion 570 and a connection portion 572. The main portiondefines a front surface 570 a, a rear surface 570 b, and a perimeteredge 570 c. Like the first connecting portion 434, the connectingportion 572 defines a connecting opening 572 a defining a bridge portion572 b. Loop structures 574 defining loop openings 574 b extend from therear surface 570 b. A lateral projection 576 that is substantially thesame as the lateral projections 460 and 462 described above also extendsfrom the rear surface 570 b. The perimeter edge 570 c is dimensioned tocomplement the perimeter edges of the lower end border part 490 and thecorner side border parts 484.

As shown in FIGS. 18A-D, the second upper side border part 494 comprisesa main portion 580 and a connection portion 582. The main portiondefines a front surface 580 a, a rear surface 580 b, and a perimeteredge 580 c. Like the second connection portion 436, the connectionportion 582 defines a neck portion 582 a and a connecting tab 582 b.Loop structures 584 defining loop openings 584 b extend from the rearsurface 580 b. A lateral projection 586 that is substantially the sameas the lateral projections 460 and 462 described above also extends fromthe rear surface 580 b. The perimeter edge 580 c is dimensioned tocomplement the perimeter edges of the upper end border part 480 and thecorner side border part 484.

Turning again to FIG. 9, it can be seen that the border portion 424 canbe held in place by a cord 590 inserted in sequence through the variousloop openings 524 b, 534 b, 542 b, 554 b, 564 b, 574 b, and 584 bdefined by the border parts 480, 482, 484, 486, 490, 492, and 494. Thecord can be elastic to allow movement of adjacent border parts relativeto each other but still maintain the integrity of the border portion424.

Although not shown in FIGS. 8 and 9 for purposes of clarity, the borderparts 480, 482, 484, 486, 490, 492, and 494 engage each other and thefield parts 430 such that connection systems are formed thatmechanically interlock the various parts 430, 480, 482, 484, 486, 490,492, and 494 to form the impact layer 420. The example impact layer 420is a diamond shape, but other shapes can be formed by altering theshapes of the perimeter edges of the various border parts.

Again, the individual impact parts 430, 480, 482, 484, 486, 490, 492,and 494 can easily be injection molded of plastic; other manufacturingtechniques and materials can be used, however, depending upon theexpected use of the impact layer.

As shown in FIG. 2, the present invention may be embodied as an exampleimpact dispersion system comprising an impact layer comprisinginterlocking impact parts, a first fabric layer comprising Kevlar, and asecond fabric layer comprising neoprene. A border is formed around theperimeter of the example impact dispersion system. The interlockingimpact parts mechanically engage each other to define the impact layer.An impact applied to any one or more of the individual impact parts isdistributed to adjacent impact parts to distribute the forces of theimpact over a relatively large surface area of the impact dispersionsystem.

FIGS. 3, 4, and 5 illustrate that the example impact parts engageadjacent impact parts end to end and side to side to mechanically engageadjacent impact parts, with edges of the adjacent impact partsoverlapping. FIG. 6 further illustrates that portions of the exampleimpact parts extend through openings in one or both of the fabric layersto mechanically engage the impact parts with the fabric layers.

FIGS. 7A-7D illustrates that the impact parts can be easily andinexpensively manufactured using conventional injection moldingtechniques.

Like the impact parts 230 and 330 described above, the impact layer 420formed by the impact parts 430 facilitates transmission of heat awayfrom the wearer through the impact layer 420. The impact parts 430 arecupped, and the cup-shaped impact parts 430 slightly deflect or deformto form a slight suction that pulls heat and moist air away from thewearer. In addition, the shapes of the impact parts 430 (e.g., pointedoval with slight inward curves towards the pointed ends) creates spacingbetween each adjacent part 430. Once the air has been forced out by thedeflection or deformation of the parts 430, the air travels through thespacings between the interconnected parts 430.

Again, like the example impact layers 222 and 320, the example impactlayer 420 may be used with a backing sheet such as the backing sheet 224described above. The perforations in such a backing sheet may be alignedwith the impact layer 420 such that air can be drawn from the inside ofthe backing sheet to the exterior, which ventilates the protectedportion of the wearer under the impact layer 420.

1. An impact assembly for protecting a wearer, comprising: first,second, and third impact parts each defining a main portion, a firstconnecting portion, and a second connecting portion; whereby the mainportion defines a first surface and a second surface; the firstconnecting portion of the first impact part engages the secondconnecting portion of the second impact part; the second surface of themain portion of the first impact part partly overlays the first surfaceof the main portion of the third impact part; and the second surface ofthe main portion of the third impact part partly overlays the firstsurface of the main portion of the second impact part.
 2. An impactassembly as recited in claim 1, further comprising a fourth impact part,wherein: the first connecting portion of the third part engages thesecond connecting portion of the fourth part; and the second surface ofthe main portion of the second impact part partly overlays the firstsurface of the main portion of the fourth impact part.
 3. An impactassembly as recited in claim 1, in which: the first connecting portionsdefine a connecting opening; and the second connecting portions define atab; and the tab extend through the connecting opening and engages thefirst connecting portion.
 4. An impact assembly as recited in claim 1,in which: at least one lateral projection extends from the secondsurface of the main portion of each impact part; and the at least onelateral projection extends through the connecting opening and engagesthe first connecting portion.
 5. An impact assembly as recited in claim4, in which: a latch portion extends from each lateral projection; andthe latch portion engages the first connecting portion.
 6. An impactassembly as recited in claim 1, further comprising a foam pad.
 7. Animpact dispersion system for protecting a wearer, comprising: an impactassembly comprising first, second, and third impact parts, wherein eachimpact part defines a main portion, a first connecting portion, and asecond connecting portion, and the main portion defines a first surfaceand a second surface; and a support structure for supporting the impactassembly over a desired area on the wearer; wherein the first connectingportion of the first impact part engages the second connecting portionof the second impact part; the second surface of the main portion of thefirst impact part partly overlays the first surface of the main portionof the third impact part; and the second surface of the main portion ofthe third impact part partly overlays the first surface of the mainportion of the second impact part.
 8. An impact dispersion system asrecited in claim 7, further comprising a fourth impact part, wherein:the first connecting portion of the third part engages the secondconnecting portion of the fourth part; and the second surface of themain portion of the second impact part partly overlays the first surfaceof the main portion of the fourth impact part.
 9. An impact dispersionsystem as recited in claim 7, in which: the first connecting portionsdefine a connecting opening; and the second connecting portions define atab; and the tab extend through the connecting opening and engages thefirst connecting portion.
 10. An impact dispersion system as recited inclaim 7, in which: at least one lateral projection extends from thesecond surface of the main portion of each impact part; and the at leastone lateral projection extends through the connecting opening andengages the first connecting portion.
 11. An impact dispersion system asrecited in claim 10, in which: a latch portion extends from each lateralprojection; and the latch portion engages the first connecting portion.12. An impact dispersion system as recited in claim 7, furthercomprising a foam pad, where the support system further supports thefoam pad.
 13. An impact assembly for protecting a wearer, comprising: aplurality of impact parts each defining a main portion, a firstconnecting portion, and a second connecting portion, where the mainportion defines a first surface and a second surface; whereby the firstand second connecting portions of a plurality of the impact parts areconnected to define a plurality of strings of impact parts; theplurality of strings of impact parts are arranged such that the secondsurface of the main portion of the some of the impact parts partlyoverlay the first surface of the main portion of others of the impactparts.
 14. An impact assembly as recited in claim 13, in which: thefirst connecting portions define a connecting opening; and the secondconnecting portions define a tab; and the tab extend through theconnecting opening and engages the first connecting portion.
 15. Animpact assembly as recited in claim 13, in which: at least one lateralprojection extends from the second surface of the main portion of eachimpact part; and the at least one lateral projection extends through theconnecting opening and engages the first connecting portion.
 16. Animpact assembly as recited in claim 15, in which: a latch portionextends from each lateral projection; and the latch portion engages thefirst connecting portion.
 17. An impact assembly as recited in claim 13,further comprising a foam pad.
 18. An impact assembly for protecting awearer, comprising: a plurality of impact parts each defining a mainportion, a connecting opening, and a connecting tab, where each mainportion defines a first surface and a second surface, and at least onelateral projection extends from the second surface of the each mainportion; whereby the connecting openings engage the connecting tabs todefine a plurality of strings of impact parts; the plurality of stringsof impact parts are arranged such that the second surface of the mainportion of the some of the impact parts partly overlay the first surfaceof the main portion of others of the impact parts; and at least onelateral projection extends through at least one connecting opening andengages the first connecting portion.
 19. An impact assembly as recitedin claim 19, in which: a latch portion extends from each lateralprojection; and the latch portion engages the first connecting portion.20. An impact assembly as recited in claim 19, further comprising a foampad.